Adapter ring for vacuum cleaner filters

ABSTRACT

A filter adapter for engaging a filter to fit the filter into a vacuum cleaner chamber. The filter adapter includes an adapter ring having an inner ring perimeter and an outer ring perimeter, and a number of protrusions extending from the outer perimeter of the ring. Alternatively, there is provided an adapter ring and filter assembly for use in a vacuum cleaner chamber. The assembly includes a filter having an outer filter perimeter, and an adapter ring having an inner ring perimeter configured to surround the outer filter perimeter and an outer ring perimeter configured to contact an inner surface of the vacuum cleaner chamber.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates to vacuum cleaners, and, more specifically, to devices for filtering dirt and other debris suctioned into vacuum cleaners.

2. Description of the Related Art

Vacuum cleaners are well known. They are devices that use an air pump to create a partial vacuum to suck up dirt and other debris, usually to clean floors and other surfaces. Vacuum cleaners come in a variety of configurations, e.g., upright, canister, robotic, central, etc. Upright vacuum cleaners typically take the form of a cleaning head, onto which a handle and bag or cyclone are attached. Upright designs usually employ a rotating brushroll or beater bar, which removes dirt through a combination of sweeping and vibration movements. Canister vacuum cleaners, on the other hand, have a vacuum head with a suction inlet (which may have a brushroll) connected to a wand, and a motor and dust collector housed in a separate unit. Typically, the separate unit is mounted on wheels and is connected to the vacuum head by a flexible hose.

Filters are used in vacuum cleaners to remove the dirt and other debris from air. One common type of filter found in vacuum cleaners is a planar filter. The planar filter is installed in a closed passage of the vacuum cleaner and is used to supplement the primary filtration device, e.g., a bag or a cyclone. A vacuum cleaner may have two or more planar filters located in separate chambers of the vacuum cleaner. For example, a “pre-motor” filter may be mounted in the airstream upstream of the suction fan, and a “post-motor” filter may be mounted in the airstream downstream of the suction fan. Planar filters typically do not have a separate dirt collection chamber associated with them—rather, they generally trap the dirt in the filter material itself.

Planar filters come in a variety of sizes and configurations, e.g., flat or curved. Such filters can use any variety of filter material. For example, filter material may be foam or pleated filter paper. Combinations of layers and materials are also frequently used. Filter material typically comes in different grades in relation to particle sizes that will be filtered by the filter material. For example, relatively coarse open-cell foam filter material may be used for filtering large particles. Conversely, filter material passing High-Efficiency Particulate Air (HEPA) or Ultra-Low Penetration Air (ULPA) standards may be used for removing smaller particles. Such filters may comprise paper or non-woven fabrics that may be impregnated with chemicals, as known in the art.

Conventionally, details of the filter to be used must be considered when designing a vacuum cleaner. Each filter in a respective vacuum cleaner is typically designed to meet the dimensional and operational specifications of the particular vacuum cleaner. These specifications may include the filter size, shape, airflow rate, dirt capacity, and filter grade of the filter.

The filter specifications can be critical to obtain proper vacuum cleaner operation. For example, if filter dimensions are not correct, the filter may be too large or too small to properly fit into the vacuum cleaner. In such cases, the user may think that the filter is properly installed, but the poor fit will may cause air leaks that result in decreased filtering efficiency, and the filter may jostle, rattle, or otherwise move in the chamber during operation of the vacuum cleaner causing unnecessary noise and possible damage. Even if the dimensions are correct, other operational characteristics may not properly match the vacuum cleaner. For example, a vacuum cleaner may be designed to operate with filter having a relatively low air impedance (i.e., the filter allows the air to pass relatively freely), and if the filter has a high impedance, it may unduly restrict the suction motor leading to higher operating temperatures, reduced cleaning efficiency, or other problems. The filter's dirt capacity also should match the vacuum cleaner's recommended maintenance schedule, so if the filter has a relatively low capacity and clogs sooner than expected, the user may be dissatisfied with the vacuum's performance.

As a result of the foregoing, vacuum cleaner filters typically are constructed to dimensionally and operationally match specific vacuum cleaner models. The inventors have found that this causes a significant burden on the process of designing and manufacturing vacuum cleaner filters. Thus, there exists a need for providing alternative approaches to providing vacuum cleaner filters.

SUMMARY

In one embodiment, there is provided a filter adapter for engaging a filter to fit the filter into a vacuum cleaner chamber. The filter adapter may include an adapter ring having an inner ring perimeter and an outer ring perimeter, and a number of protrusions extending from the outer perimeter of the ring.

In another embodiment, there is provided an adapter ring and filter assembly for use in a vacuum cleaner chamber. The assembly may include a filter having an outer filter perimeter, and an adapter ring having an inner ring perimeter configured to surround the outer filter perimeter and an outer ring perimeter configured to contact an inner surface of the vacuum cleaner chamber.

The recitation of this summary of the invention is not intended to limit the claims of this or any related or unrelated application. Other aspects, embodiments, modifications to, and features of the claimed invention will be apparent to persons of ordinary skill in view of the disclosures herein.

BRIEF DESCRIPTION OF THE DRAWINGS

The invention is best understood from the following detailed description when read in connection with the accompanying drawings, with like elements having the same reference numerals. Included in the drawings are the following figures:

FIG. 1 is an isometric view of an exemplary ring assembly that may be used to adapt a filter to a particular vacuum cleaner.

FIG. 2 is an isometric view of a filter that engages with the exemplary ring assembly of FIG. 1.

FIG. 3 is an isometric view of the exemplary ring assembly of FIG. 1 engaged with the filter of FIG. 2.

FIG. 4 is an isometric view of an embodiment of a rib-less ring assembly.

FIG. 5 is an isometric view of an embodiment of a ring assembly having a plurality of clamps for engaging the filter of FIG. 2.

FIG. 6 is an top view of an alternative ring assembly having a rectangular shape.

DETAILED DESCRIPTION

It has been found that the process of designing and manufacturing vacuum cleaner filters can be expedited and simplified by modifying vacuum cleaner filters to operate in multiple different vacuum cleaners. The following embodiments describe unique exemplary arrangements for providing adapter rings for vacuum cleaner filters. It will be appreciated that embodiments may be used upright, canister, robotic, stick, central, and other kinds of vacuum cleaner, and also that embodiments may be used for pre-motor or post-motor filters.

FIG. 1 illustrates an exemplary adapter ring 100. The adapter ring 100 is configured to engage a filter that removes dirt and other debris suctioned by a vacuum cleaner. In an exemplary embodiment, adapter ring 100 will engage with a filter to enlarge the effective circumference of the frame of the filter. By enlarging the circumference of the filter, the filter may be adapted to properly fit into a particular vacuum cleaner, other than the vacuum cleaner in which the filter was originally designed to fit. For example, a filter having a diameter that is otherwise too small for a particular vacuum cleaner filter chamber may be adapted by the adapter ring 100 to properly fit within the chamber. The shown embodiment increases the effective circumference of a circular filter to fit into a larger circular chamber, but other embodiments may change the effective perimeter shape, such as by converting a circular filter to fit into a square chamber.

As depicted in FIG. 1, adapter ring 100 includes an outer perimeter 102 and an inner perimeter 104. The inner perimeter 104 is configured to engage a filter having a similar outer surface shape. In the embodiment of FIG. 1, the inner perimeter 104 is annular, to engage a filter also having an annular outer surface. However, an adapter ring 10 may be shaped (and sized) in any manner necessary to engage a particular filter. For example, alternative embodiments of the present invention may include a ring that is rectangular (FIG. 6), square, polygon, oval, etc. Further, an adapter ring 100 may be sized to engage with a filter of various sizes to fit within particular vacuum cleaners and may be formed of any material that suitably engages with a filter. For instance, inner perimeter 104 may be formed of plastic, metal, rubber, etc., to engage with outer perimeter 202 of filter 200 (FIG. 2). It will be appreciated that inner perimeter 104 need not exactly match the entire outer perimeter 202 of the filter 200, but it should match enough of the outer perimeter 202 to engaged the filter 200 to remain in place during installation into the vacuum cleaner and during use.

In an exemplary embodiment, at least one rib extends outwardly from outer perimeter 102 of adapter ring 100. In a preferred embodiment, at least three ribs, e.g., ribs 106, 108, 110 extend outwardly from adapter ring 100. Ribs 106, 108, 110 may be spaced about the adapter ring 100 equidistantly from each other. In other embodiments, ribs may be spaced from each other in varying distances. Ribs 106, 108, 110 may extend perpendicularly from the outer perimeter 102 of adapter ring 100. However, ribs may extend in any direction or formation, e.g., horizontally, diagonally, cross-wise, etc. Ribs 106, 108, 110 are intended to enlarge the circumferential size of filter 200 to adapt filter 200 to properly fit into a particular vacuum cleaner. In one embodiment, ribs 106, 108, 110 are a plastic material. However, adapter ring 100 may be made of any other suitable material, such as metal, rubber, etc.

The ribs may have any size or shape to adapt a filter to a particular chamber of a vacuum cleaner. In the embodiment of FIG. 1, the ribs 106, 108 extend between an upper edge 112 and a lower edge 114 of the adapter ring 110, and have rounded corners 116 at each end where the ribs 106, 108, 110 terminate ad the upper and lower edges 112, 114. Other ribs, however, may be have different shapes, and may include straight lines, jagged edges, curves, angles, etc. The ribs also may not extend entirely from the upper edge 112 to the lower edge 114, or may extend beyond one or both edges 112, 114. The ribs also may be angled or perpendicular to the shown ribs (e.g., a rib may be provided as an annular wall that extends from the outer perimeter 102 around all or some of the outer perimeter 102). One of ordinary skill in the art will understand the sizes and shapes that the ribs may take to adapt a filter for properly fitting the filter into a particular vacuum cleaner.

Inner perimeter 104 of adapter ring 100, and outer perimeter 102 of adapter ring 100, may be shaped and sized similarly. For instance, both inner perimeter 104 and outer perimeter 102 may be shaped annularly. However, in alternative embodiments, inner perimeter of ring and outer perimeter of ring may take on shapes and sizes that are different from one another. Such difference in size between inner perimeter 104 and outer perimeter 102 may result in various thicknesses of the ring (and the adapted filter). This thickness between outer perimeter 102 and inner perimeter 104 may be configured to vary according to the particular vacuum cleaner that the filter is being adapted to fit. For example, if a large spacing is present between filter 200 and a wall of the vacuum cleaner chamber, the thickness of adapter ring 100 may be increased accordingly.

Adapter ring 100 engages filter 200 when inner perimeter 104 of adapter ring 100 contacts outer perimeter 202 of filter 200 (FIG. 2). In an exemplary embodiment, outer perimeter 202 of filter 200 defines the circumferential size of filter 200. The circumferential size of outer perimeter 202 may be used to determine the sizing of filter 200 with respect to a particular vacuum cleaner. If the circumference of outer perimeter 202 is too large, for example, filter 200 will not be placeable into the chamber of the vacuum cleaner. Conversely, if the circumference of outer perimeter 202 is too small for a particular vacuum cleaner, filter 200 will jostle, rattle, or otherwise move laterally or vertically within the vacuum cleaner. As it does so, it may no longer seal properly with the airflow passages that direct air to or from the filter 200.

In the shown embodiment, the filter's outer perimeter 202 is defined by the filter's frame 206. Frame 206 may be formed of any material typically used for frames of a filter, such as plastic. The frame 206 may extend the full height of the filter 200, and may include other features, such as a cross-shaped structure at the top of the filter 200 having a handle 208 that may be used to insert and remove the filter 200 from the filter chamber. The handle 208 also may be used to orient the filter 200 or for other purposes as known in the art.

The filter 200 also includes a filter element 204. Filter element 204 may be formed of any material typically used for filtering dust or other debris. For example, filter element 204 may be paper, fiberglass, foam, etc. As depicted in FIG. 2, filter element 204 is located within frame 206. The performance of a particular filter is typically defined by the filter grade of filter element 204. A foam filter element 204, for example, may be graded to filter relatively large particles, whereas a filter element 204 conforming to High-Efficiency Particulate Air (HEPA) or an Ultra-Low Penetration Air (ULPA) standards, may be graded to filter relatively small particles. The filter element 204 may include multiple layers of similar or dissimilar filter material, as known in the art. In some cases, the filter element 204 may have sufficient structural properties that a frame 206 is not necessary or used.

In the example if FIG. 2, the filter 200 also includes a bottom portion 210 made from an extension of the frame 206. The bottom portion 210 may be provided to seal against a chamber wall, and may include a lower seal 212 that seals around an exhaust or inlet passage of a vacuum fan. In an exemplary embodiment, depicted on FIG. 2, bottom portion 210 may flare away from filter 200. In such an embodiment, bottom portion 210 will have a circumference larger than the circumference of outer perimeter 202.

As shown in FIG. 3, adapter ring 100 engages with filter 200. In particular, inner perimeter 104 of adapter ring 100 engages with outer perimeter 202 of filter 200. The circumference of inner perimeter 104 is configured to be slightly larger than the circumference of outer perimeter 202 so that adapter ring 100 slides into place around outer perimeter 202. The sizes of the parts may be selected to provide a removable connection (e.g., a slight friction fit or deformable snaps), or to provide a permanent connection (e.g., a tight friction fit or snaps that do not permit removal). In an exemplary embodiment, adapter ring 100 is engaged with filter 200 by lightly pressing adapter ring 100 upon and about outer perimeter 202 of filter 200. When adapter ring 100 is engaged to filter 200, adapter ring 100 preferably fits snugly upon filter 200 so that it does not jostle, rattle, or otherwise be displaced from filter 200 during normal use and handling. When inner perimeter 104 of adapter ring 100 is fit upon outer perimeter 202 of filter 200, the lower edge 114 of adapter ring 100 abuts against the upper part of bottom portion 210 of filter 200.

As noted above, the exemplary adapter ring 100 includes a plurality of ribs 106, 108, 110 that extend outwardly from adapter ring 100 to enlarge the effective circumference of adapter ring 100. When adapter ring 100 is engaged with filter 200, filter 200 will also have a larger effective circumference. Where it is desired to fit the filter 200 to a larger circular chamber, the use of three or more ribs 106, 108, 110 is preferred, as making three contact points to the inner surface of the circular chamber will effectively resist movement in any direction in the plane of the filter 200. However, two diametrically-opposed ribs alternatively may be used, which may provide good support, but also may be more subject to forces applied perpendicular to the line formed between the two ribs. The use of more than three ribs may be used in any event, and may be helpful to hold the filter 200 in a chamber that has an irregular or non-circular shape. Other variations and modifications will be apparent to persons of ordinary skill in the art in view of the present disclosure.

In alternative embodiments, such as the example of FIG. 4, an adapter ring may have no ribs. Adapter ring 400 is sized and shaped such that it expands the circumference of filter 200 without one or more ribs extending from the adapter ring 400. Rather, the thickness of adapter ring 400 determines whether a filter 200 will be adapted to properly fit into a vacuum cleaner. In such cases, the circumference of outer perimeter 402 of adapter ring 400 is sized such that filter 200 will properly fit inside a particular vacuum cleaner chamber. In this case, the outer perimeter 402 may be a smooth shape (i.e., uninterrupted by ribs or the like) that continuously contacts a correspondingly-shaped vacuum cleaner chamber, and may also provide an air seal. As a result, the filter will not jostle, rattle, or otherwise move in an undesired way. Adapter ring 400 may be formed of foam, although other materials may be used for the ring.

In the embodiment of FIG. 4, adapter ring 400 engages filter 200 by wrapping around the enlarged bottom portion 210 of filter 200. In this embodiment, the adapter ring 400 has a bottom portion 406 that extends around the lower edge of the filter's bottom portion 210, and an inner surface 404 that overlies the vertical side of the filter's bottom portion 210, and an upper portion 408 that extends around an upper side of the filter's bottom portion 210. Thus, adapter ring 400 engages with filter 200 to that they will not separate during handling or use. Instead, ring 400 will only disengage when the user pulls top portion 408 and/or bottom portion 406 of ring 400 far enough to allow the filter 200 to be removed. The top and/or bottom portion 408, 406 may be formed of a pliable material, such as foam, rubber or soft plastic, to allow installation and removal.

In another embodiment, the adapter ring 400 may comprises a simple ring that fits over the upper part of the filter 200. For example, the adapter ring 400 may comprise a circular foam block with a hole sized to fit over filter 200. Other variations and modifications will be apparent to persons of ordinary skill in the art in view of the present disclosure.

Another alternative embodiment of an adapter ring 500 is depicted in FIG. 5. Adapter ring 500 includes at least one clamp for attaching adapter ring 500 to filter 200. In a preferred embodiment, adapter ring 500 will have at least three clamps 506, 508, 510 for engaging adapter ring 500 to filter 200. Clamps 506, 508, 510 attach to bottom portion 210 of filter 200. Clamps 506, 508, 510 are used to securely affix adapter ring 500 to filter 200. Clamps 506, 508, 510 are also used to enlarge the effective circumference of filter 200. To securely affix each clamp 506, 508, 510 to filter 200, adapter ring 500 includes, on clamp inner surface 518, a flange or other member for affixing adapter ring 500 to filter 200. For example, as depicted on FIG. 5, clamp 508 includes a horizontally extending coupling member 516 for engaging adapter ring 500 to bottom portion 210 of filter 200. However, coupling member 516 may affix to the side, bottom, or any other surface of filter 200.

Clamps 506, 508, 510 also include clamp outer surface 520. In an exemplary embodiment, clamp outer surface 520 includes at least one rib extending outwardly from clamp outer surface 520 (e.g., vertically extending ribs 512, 514 of clamp 510). Ribs 512, 514 may be used to enlarge the effective circumferential size of adapter ring 500. Thus, when adapter ring 500 is engaged with filter 200, the effective circumference of filter 200 is enlarged by way of the outwardly extending ribs. As discussed above, by enlarging the effective circumference of filter 200, adapter ring 500 permits filter 200 to be properly sized for a particular vacuum cleaner, e.g., adapter ring 500 prevents filter 200 from jostling, rattling, or otherwise moving when the vacuum cleaner is in operation.

In some embodiments, inner perimeter 504 of adapter ring 500 may assist in coupling adapter ring 500 to filter 200. In particular, inner perimeter 504 will fit over, and engage with, outer perimeter 202 of filter 200. To ensure a snug fit of adapter ring 500, inner perimeter 504 of adapter ring 500 should be slightly larger than outer perimeter 202 of filter 200, as discussed above for adapter ring 100. Thus, inner perimeter 504, in combination with clamps 506, 508, 510, will ensure adapter ring 500 is snugly fit upon filter 200. Thus, adapter ring 500 will not disengage from filter 200 during normal operation of the vacuum cleaner. To release adapter ring 500 from filter 200, clamps 506, 508, 510 may be pulled away from bottom portion 210 of filter. This movement of clamp will separate coupling member 516 from bottom portion 210 of filter.

Although FIGS. 1 and 3-5 have depicted rings having an annular shape, alternative embodiments for a ring of the present invention should not be so limited. Alternative embodiments of the ring of present invention may include, for example, many different shapes and sizes for adapting a filter to a particular vacuum cleaner. For example, a ring may be shaped as a parallelogram, oval, rhombus, etc. As depicted on FIG. 6, an adapter ring 600 may be rectangular (i.e., approximately the shape of a geometric rectangle). Thus, in this embodiment, adapter ring 600 may be used to engage with a filter (not shown) that is rectangular.

FIG. 6 depicts adapter ring 600 having an inner perimeter 604 and outer perimeter 602. Inner perimeter 604 engages the outer perimeter of a rectangular filter. An embodiment of adapter ring 600 will be sized and shaped such that it will snugly engage the rectangular filter, e.g., ring will be sized and shaped so that it will not jostle, rattle, or otherwise move during use of the vacuum cleaner. In one embodiment, inner perimeter 604 of adapter ring 600 should be substantially the same size as its corresponding filter, although adapter ring 600 should be a predetermined size larger than the outer perimeter of a corresponding rectangular filter. Such sizing of adapter ring 600 will ensure that adapter ring 600 is properly engaged with the filter.

Adapter ring 600 also includes a plurality of ribs, e.g., 604, 606, 608, 610, attached to outer perimeter 602. In an exemplary embodiment, at least four ribs will extend outwardly from adapter ring 600. Ribs 604, 606, 608, 610 are sized to ensure that the filter engaged with adapter ring 600 properly fits into a chamber of a particular vacuum cleaner. As such, the filter will be snugly held into place within a vacuum cleaner. The outwardly extending ribs 604, 606, 608, 610 will contact the housing within the vacuum cleaner to ensure the filter provides a proper fit for a particular vacuum cleaner.

The present disclosure describes a number of new, useful, and nonobvious features and/or combinations of features that may be used alone or together. The embodiments described herein are all exemplary, and are not intended to limit the scope of the inventions. Persons of ordinary skill in the art will appreciate and understand that the inventions described herein can be modified and adapted in various and equivalent ways, and such modifications and adaptations are intended to be included in the scope of this disclosure and the appended claims. 

What is claimed:
 1. A filter adapter for engaging a filter to fit the filter into a vacuum cleaner chamber, the filter adapter comprising: an adapter ring having an inner ring perimeter and an outer ring perimeter; and a plurality of protrusions extending from the outer perimeter of the ring.
 2. The filter adapter of claim 1, wherein the plurality of protrusions comprises at least three ribs.
 3. The filter adapter of claim 2, wherein each of the at least three ribs extends in a different respective direction and the at least three ribs are spaced equidistantly around the adapter ring from one another.
 4. The filter adapter of claim 1, wherein the inner ring perimeter is configured to engage a corresponding outer perimeter of the filter.
 5. The filter adapter of claim 4, wherein the inner ring perimeter frictionally engages the outer perimeter of the filter.
 6. The filter adapter of claim 1, wherein the plurality of protrusions are configured to contact the vacuum cleaner chamber at at least three points.
 7. The filter adapter of claim 1, wherein the adapter ring includes clamps configured to couple the adapter ring to the filter.
 8. The filter adapter of claim 7, wherein each clamp includes a coupling member on an inner surface of the clamp, and a flange on an outer surface of the clamp.
 9. The filter adapter of claim 7, wherein the clamps comprise at least three clamps.
 10. The filter adapter of claim 1, wherein the inner ring perimeter comprises a circle.
 11. The filter adapter of claim 10, wherein the inner ring perimeter is configured to engage a corresponding circular outer perimeter of the filter.
 12. The filter adapter of claim 1, wherein the inner ring perimeter comprises a polygon.
 13. An adapter ring and filter assembly for use in a vacuum cleaner chamber; the assembly comprising: a filter having an outer filter perimeter; an adapter ring having an inner ring perimeter configured to surround the outer filter perimeter and an outer ring perimeter configured to contact an inner surface of the vacuum cleaner chamber.
 14. The adapter ring of claim 13, wherein the outer ring perimeter comprises a plurality of ribs.
 15. The adapter ring of claim 14, wherein the plurality of ribs comprises at least three ribs.
 16. The adapter ring of claim 13, wherein the adapter ring comprises a plurality of clamps that each surround a respective portion of the outer filter perimeter.
 17. The adapter ring of claim 16, wherein each of the plurality of clamps comprises at least one rib extending radially from the outer ring perimeter.
 18. The adapter ring of claim 13, wherein the adapter ring comprises a smooth outer perimeter configured to contact the inner surface of the vacuum cleaner chamber continuously around the outer perimeter.
 19. The adapter ring of claim 18, wherein the inner ring perimeter is configured to surround an enlarged portion of the outer filter perimeter.
 20. The adapter apparatus of claim 18, wherein the ring comprises foam. 